Cutting edge fabric filer design the fl smidth duo clean technology further enhanced [compatibility...

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.

Cutting Edge Fabric Filer Design -The FLSmidth DuoClean TM

And conversion from ESP to FF

- technology enhanced further.

Air pollution control solutionsby Henrik Vittrup Pedersen

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 23-04-2015 2AFCM - 2015 - Innovation in fabric filter design

CLEANER TECHNOLOGY

Contents

� DuoClean™ filter

� A proven technology

� Innovative modular design

� Research & Development activities

� Full scale pilot test

� Computational Fluid Dynamic analysis

� A popular design

� Cases and results

� Conversion of ESP to Fabric Filter.

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 3AFCM - 2015 - Innovation in fabric filter design

“The goal was to develop a compact filter which is simple to manufacture, transport and install while still delivering low operational costs, high performance and low emission. With the new, modular DuoClean filters the extensive focus on manufacturability and constructability also means that the filters minimize environmental footprint.”

Mr. Lars Gamborg, Global Product Manager, Fabric filters

New modular filter designto reduce CAPEX

23-04-2015

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 4

DuoClean fabricfilter technology

AFCM - 2015 - Innovation in fabric filter design

CLEANER TECHNOLOGY

� One compartment filter

� Dual gas flow approach, from side and bottom of the bags

� Unique gas distribution screens

� Long filter bags up to 12m

� Low can velocity and dustre-entrainment

� Pre-separation of dust before the bags

23-04-2015


CLEANER TECHNOLOGY

� Ideal for processes with high dust load or when on-line maintenance isnot required

� > 50 filters installed worldwide between 2007 and 2014 all with outstanding performances

23-04-2015

Manifold withguide plates

Screenbetweenmanifoldand bags

Hopper restriction(flow adjustment)

DuoClean fabricfilter technology


Perspectives indesign principles


CLEANER TECHNOLOGY

1. Technology development � FLSmidth on-line cleaning system� Unique gas distribution system� FLSmidth long bag technology

2. Modular design � Standard engineering� Reduced number of components

3. Cost-effectiveness� Casing design reduces steelwork usage� Small footprint, best fit

4. Optimization from workshop to site � Manufacturing - easy production� Transportation - panels fit the container size� Installation - cost-effective assembly

23-04-2015

→ Reduce OPEX

→ Reduce CAPEX

→ Low weight &Reduce CAPEX

→ Manufacturability & Constructability


CLEANER TECHNOLOGY

� Multi-octagonal shaped casing

� Medium to large gas flows (150.000 – over 1.000.000 Am3/h)

� Ideal for cement kiln and mill filters

� Bag length up to 12 m

� Up to 15% reduction in steelwork thanks to casing design

Matching larger needsDuoClean DC2

23-04-2015

Manifold withguide plates

Side distribution screens


Reduced operational costs


CLEANER TECHNOLOGY

� Unique gas distribution ensures a uniform gas velocity and minimized wear of the filter bags

� The optimized pulse jet system and the possibility to clean with low pressure (P ≤ 2.0bar) reduces compressed air consumptions and the stress of the bags thus increasing bag lifetime

� The absence of dampers means reduced pressure drops leading to reduced energy consumption of the ID fan

23-04-2015 8


Optimized fabrication and transportation


CLEANER TECHNOLOGY

� Casing plate span is reduced by 30-40% allowing to use simple reinforcement profiles - reduces the fabrication time

� Concept of standardization makes it easy to manufacture filter parts - reduces the risk of errors

� Steel parts are designed for maximizing loading of standard containers – ensures optimized transportation at reduced cost

23-04-2015 99


Easy assembly of identical modules


CLEANER TECHNOLOGY

23-04-2015 10

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.AFCM - 2015 - Innovation in fabric filter design

CLEANER TECHNOLOGY

23-04-2015

Weights DuoClean DuoClean DC2 Comparison

Supports (tons) 16,1 18,2 +13%

Casing, hoppers, top boxes (tons)

84,1 71,6 -14,9%

Access (tons) 6 6 0%

Penthouse (tons) 9,6 8,2 -14,6%

Insulation (tons) 22,2 21,9 -1,4%

Components (tons) 40,1 34,5 -14%

Total 178 160,4 -9,9%

Footprint

Supporting structures (m2)

117,5 87 -26%

11

DuoClean vs. DuoClean DC2

11


� Pilot filter with 10m long bags

� Testing at different process conditions

� Testing of different type of purge valves

� Testing of low pressure cleaning system

CLEANER COMPETENCE – R&D

23-04-2015AFCM - 2015 - Innovation in fabric filter design

Full scale testing facilities at FLSmidth R&D Center, Dania




Low pressure cleaning –Fine tuning of parameters

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 14AFCM - 2015 - Innovation in fabric filter design 23-04-2015


Velocity m

agnitude

0 to 24 m

/s scale bar

Velocity m

agnitude

0 to 14 m

/s scale bar

Mid plane of filter

Vertical cross section of inlet manifold

In-house Computational Fluid Dynamic (CFD) investigations

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws. 15AFCM - 2015 - Innovation in fabric filter design 23-04-2015


Velocity m

agnitude m

/s

Velocity distribution at 4500mm above the bottom

of the bagsMid-plane cross sections in

hoppers

CFD results – DC2 Gas distribution



Pulse jet cleaning system

Nozzles testing

CFD developments – Cleaning system



Venturi testing

CFD developments – Cleaning system


� Turnkey supply of DuoClean DC2 filter for kiln/raw mill process

� Cement production knowledge, extensive R&D and compact design were key drivers for Lafarge to select FLSmidth as supplier

� Performance test show emission level well below the guarantee at 2.25 mg/Nm3

18

CLEANER SOLUTIONS – CASE

Lafarge Medgidia, Cement, RomaniaDuoClean DC2

“FLSmidth is a well known supplier in the cement industry. When we selected the DuoClean DC2 filter we knew that we could expect high quality, a high performing installation and professional service during the project execution”

Emmanuel Ollivier, Project ManagerLafarge Technical Center



� Turnkey supply of DuoClean DC2 filter for kiln/raw mill process

� Maintenance and stocking of spare parts is simplified as the filter is identical to the filter at Medgidia

� Performance test show emission level well below the guarantee at 1.24 mg/Nm3

19

CLEANER COMPETENCE – CASE

Lafarge Rezina, Cement, MoldovaDuoClean DC2



� Supply of DuoClean DC2 filter for cement mill process

� The DC2 filter was selected thanks to its compact design and optimised performance handling large gas flow

20

CLEANER COMPETENCE – CASE

Askale Gumushane, TurkeyDuoClean DC2



Air Pollution Control solutionsConversion of ESP to fabric filter


Conversion from ESP to fabric filters

23-04-2015

Why convert?

� Mechanical or electrical equipment is worn out

� Production has increased

� New emission requirements

� Change in fuel or raw material

Advantages

� Short plant stop time

� Low investment cost

� Reduced delivery time

� Reuse of existing equipment (supporting structure, dust transport, fan, etc.)

� Flexible design for all makes of ESP’s

� Reuse of existing control system for auxiliary equipment

AFCM - 2015 - Innovation in fabric filter design 22



Configuration examples

23-04-2015

Cleaning:

Online

Maintenance:

Offline

Example A

One dirty gas chamber.

One clean gas chamber.

No dampers.

Many dirty gas chambers.

Many clean gas chambers.

With inlet and outlet dampers.

Example B

Cleaning:

Online or Offline

Maintenance:

Online




Configuration examples

23-04-2015

Example C

Hybrid filter.

Combined ESP and FF.

Example D One dirty gas chamber.

One clean gas chamber.

With outlet dampers.

Cleaning:

Online or Semi-Offline

Maintenance:

Offline (one top box can be

taken out)




Overview of options

Fabric filter Online

Fabric filter Semi-online

Fabric filter Offline

Hybrid

CompartmentsYes Yes No

Yes,if semi-offline

Hopper modificationrequired

Yes No No No

Maintenance in operation

Yes No No No

Pressure drop (mmWg)

130 – 150 130 - 150 120 - 150 100 - 120

Sensitive to CO No No No Yes

Compressed air consumption index

100 100 100 70

Bagsreplacement time (estimate)

2 years (felt bags) 5 years (fiberglass)




Cost index 100 95 75 60

23-04-2015 25AFCM - 2015 - Innovation in fabric filter design



Main equipment, Top Box

23-04-2015

Tube sheet




Site pictures

23-04-2015

Empty casing – day 7ESP plates/electrodes dismantling – day 3-5




Site pictures

23-04-2015

Gas distribution screens – Day 16-19 Gas distribution screens – Day 16-19




Site pictures

23-04-2015

Top boxes installed – Day 23 Bags & cages installation – Day 23-25




Site pictures Siam Cement Thung Song

23-04-2015AFCM - 2015 - Innovation in fabric filter design 30



Site pictures



Siam Cement Thung Song


Thank you for your attention

www.flsmidth.com/apc


Date post:	15-Jul-2015
Category:	Business
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Cutting edge fabric filer design the fl smidth duo clean technology further enhanced [compatibility...

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